Method and apparatus for shaping plastic foam insulation board to fit roof contours

ABSTRACT

A foam board insulation shaping system and method for hot wire shaping insulation board to fit roof contours, wherein a frame mounts a transversely disposed, generally horizontal, linear wire and conveying rolls move the foam board along a longitudinal pathway past the wire, which melts the plastic as the board moves. Wire clamps secure the ends of the wire and are mounted for vertical movement, one of the wire clamps being also mounted for transverse movement relative to the frame. Yieldable mechanism associated with one of the clamps provides for expansion of the wire linearly with heating, while maintaining it under tension. A motor drives the clamps to move them vertically in unison at a predetermined speed with relation to the speed of the board. A series of transversely spaced, generally U-shaped hot wires are provided for forming grooves in the upper surface of boards, and means are provided for electrically energizing the linear wire and the U-shaped wires.

This is a continuation of copending application Ser. No. 885,273, filedon July 14, 1986, now abandoned.

BACKGROUND OF THE INVENTION

This invention relates generally to readily portable, insulation boardshaping machinery, and more particularly to the hot wire shaping ofinsulation board to fit varying roof contours. Membrane roof systems ofthe type which are custom fit to the particular roof in the factory, andthen installed at the job site to fashion an integrated one-piece roofcovering, are being sold in ever-increasing numbers as roof coveringsfor flat and relatively shallowly pitched roofs. Such roof systemscomprise a single-ply, flexible membrane of the type wherein a polyesterscrim or fabric is ensheathed between thermoplastic top and bottomlayers which permit easy seam welding at the job site, where the variousprefabricated pieces are assembled and joined using hot air weldingtechniques, and secured in position on the underlying roof.

Frequently, the underlying roof comprises a corrugated metal roof panelhaving parallel ribs and valleys. When such metal decks are covered,either in new or existing structures, it is desirable to utilizeinsulation board between the metal deck and overlying membrane toprovide insulation qualities as well as a smooth surface over which themembrane may be applied. It is, moreover, necessary to provide taperedinsulation boards which, for example, decrease gradually in thickness ina sloped roof from the ridge line to the outer edge of the roof. In someinstances it is necessary to provide compoundly tapered boards, i.e.,tapered transversely, as well as longitudinally.

The shaping of the insulation boards to fit the roof contour, in themanner required, is a task best carried on at the work site, where thedimensions are relatively easily ascertainable, and fine adjustments canbe made to achieve the required fit, since underlying roof decks areusually not normally exactly dimensionally uniform in character.

The machine to perform the various shaping jobs which are necessaryshould be readily portable in the sense that it can be moved from worksite to work site, and the machine to be described has been designed sothat it can be readily transported in a pick-up truck.

SUMMARY OF THE INVENTION

One of the prime objects of the present invention is to design a machinecapable of providing both corrugations and tapers that are simple orcompound.

Another object of the invention is to design a machine which readilybreaks down into several discrete assemblies which can be readilytransported in a common pick-up truck.

Still another object of the invention is to provide a machine, of thecharacter indicated, which is particularly suited to providingunderlying insulation for mechanically fastened single-ply plasticmembrane roof covering systems.

Another object of the invention is to provide a shaper for roofingcontractors which can readily be set up at the job site, to providecorrugated and tapered surfaces of the dimensions required for aparticular roof in a rapid and economic manner.

A further object of the invention is to provide a machine of thecharacter described, which is readily set up to provide a compoundtaper, where this is required.

Still another object of the invention is to provide a machine whichrelatively unskilled workmen can easily operate.

Another object of the invention is to provide a machine in which a novelwire clamp assembly provides for maintaining a tension on thetaper-forming hot wire, as it heats and expands, to maintain it in atruly linear taut condition, which provides the desired precisionshaping required when cutting tapered contours.

Still a further object of the invention is to provide a system of thecharacter described, which is capable of providing a variety of shapeswith readily adjusted elements which are of such structure as to lendthemselves to the shaping of the various contours required.

Another object of the invention is to provide a system wherein thetaper-cutting wire is moved at a controlled speed correlated with thefeed at which the insulation boards are moved past the hot wire element.

Other objects and advantages will become apparent by reference to thedrawings, and the following specification.

IN THE DRAWINGS

FIG. 1 is an schematic isometric, elevational view showing the machineset up and cutting parallel grooves in an elongate plastic foaminsulation board which is being fed through the machine;

FIG. 2 is a fragmentary, isometric view illustrating the manner in whichthe insulation board shaped in the machine is fitted to an underlyingcorrugated metal deck;

FIG. 3 is a fragmentary, side elevational view, taken on the line 3--3of FIG. 1;

FIG. 4 is a sectional plan view, taken on the line 4--4 of FIG. 3;

FIG. 5 is an enlarged, fragmentary transverse sectional view, taken onthe line 5--5 of FIG. 3;

FIG. 6 is an enlarged, fragmentary, side elevational view, taken on theline 6--6 of FIG. 4;

FIG. 7 is a partly sectional view of one of the wire end holding boltmembers;

FIG. 8 is a schematic end elevation of a foam board which has been cutwith a transverse taper; and

FIG. 9 is a longitudinal view of a board being cut with a longitudinaltaper.

Referring now more particularly to the accompanying drawings, andparticularly in the first instance to FIG. 2, a portion of a roofstructure, generally designated R is shown, consisting of a series ofparallel purlins 10, over which a metal deck 11 is secured, deck 11,including upstanding transversely spaced apart longitudinal ribs orcorrugations 12. To permit a one-piece, flat, plastic membrane to besecured in position as a roof cover, a plastic foam insulation board 13is provided with U-shaped recesses 14, to fit the corrugations or ribs12. Because, the board 13 must be level, it is necessary that the fit bea good one so that one side of the board 13 is not raised, for example,with respect to the other side. If the recess 14 at one side of theboard is either too small or too large, one side of the board is raisedwith respect to the other.

A machine which will permit the roofing contractor to custom-shape hisinsulation board at the job site, is disclosed in the remaining figures,and particularly is shown in operation in FIG. 1, cutting the recesses14 in the plastic board 13 from end-to-end longitudinally. The portablemachine disclosed comprises a demountable, entrance table or platform,generally designated 15, a central shaping unit 16, and a dischargetable or platform 17. It is to be understood that the tables 15 and 17are detachable from the central unit 16 and foldable. Briefly, eachtable 15 and 17 includes single leg structures 18, with decks orplatforms comprising side angle members 19, connected by end members 20,which are further connected by longitudinal rails 21.

Each of the table members 15 and 17 is provided with brackets 22, whichcan demountably bolt, as at 23, to brackets 24 provided at the sides ofthe central shaping unit 16. Insulation board 13 is placed by hand, orfed by conveyor, to the infeed table unit 15, and fed through unit 16,in a manner which will be disclosed, to the discharge table 17, fromwhich it may be manually or mechanically removed. The shaping unit 16comprises a frame, generally designated F, which is mounted on casterwheels 25, depending from a base, generally designated B. A pair ofupright columns 26 are provided at the sides of the frame F, and areconnected at their upper ends by sill members 27.

Mounted at the entrance end of the frame F, in bearings 28 (see FIG. 3)secured to the uprights 26, are the shaft ends 29 of a drive roll 30,which as FIG. 3 indicates, may be driven in the clockwise direction by asprocket 31. At the discharge end of the frame F, the shaft ends 32 of adrive roll 33 are journaled in bearings 34 fixed to uprights 26 at eachside of the machine, and it will be seen that the roll 33 is driven inthe same clockwise direction of rotation via a sprocket 35. Sprocket 35may be driven by a chain 36, via a sprocket 37 mounted on the outputshaft 38 of a reversible electric motor 39. The sprocket 31 is alsodriven by the chain 36, via a sprocket 40, mounted on the shaft end 32,and a chain 41 which is trained around both sprocket 40 and sprocket 31.

Provided to assist drive roll 30, at the entrance end of the machine, isan upper pressure roll 42, having shaft ends 43 journaled in bearings44, which are fixed to channel guide members 45 at each side of themachine, and move upwardly and downwardly with the guides 45 on theupright columns 26 of frame F.

Mounted on the bearing 44, at each side of the machine, is a connectingmember 47 having an opening 48 under which a threaded nut 49 is fixed.The nuts 49, at each side of the machine, receive an adjusting shaft 50,which is threaded at its lower end as at 50a, and extends up through abearing opening 51 provided in an upper connecting sill 26a. Amanipulating handle 52 is provided on the upper end of each shaft 50,each shaft 50 being rotatable but axially fixed in any suitable mannerby members such as collars 53 and 54.

At the discharge end of the central unit 16, a similar pressure roll 56is provided, with its shaft ends 57 journaled in bearings 58 provided onsimilar, suitably mounted, channel-shaped guides 59, which embrace andguide on the uprights 26 at that end of the frame at each side. As atthe entrance end, connecting members 60 are provided fixed to bearings58, and each has an opening 60a to pass an adjusting shaft 61. A similarnut 62 is fixed to each connector 60 below each opening 60a, and it willbe seen that the lower end of the shaft 61 is threaded as at 61a, suchas to be actuably received by the nut 62. At its upper end each shaft 61may be provided with a hand wheel 63 for purposes of rotating shaft 61,which is similarly restrained from movement in an axial direction bycollars 64 and 65. Plainly, rotation of the shaft 61 will raise the endsof the pressure roll 56 in unison. Supports 66 are fixed to the guides59 at each side of the machine to support cross rails 68, which connectthem and extend transversely beyond them to connect with the upwardextensions 67 on members 60. Mounted on the members 68 at spacedintervals, are hot wire carrying plates 69 (FIG. 5) which havevertically extending adjustment grooves 70 provided in them. Channels71, secured in adjusted positions on the plates 69 by bolt and nutsecuring assemblies 69a, which extend through the grooves 70, mount theplates 69 in vertically adjusted position. On the lower ends of plates69, are the non-conductive bars 69b from which U-shaped, hot wires 72,depend in position to form the grooves 14 in the insulation board 13.The wires 72 are of a flexible nature and can be bent to the desiredshape. To maintain rigidity, it is to be observed that the channelmembers 71 are snugly engaged within the projecting flanges 68a of anglemembers 68.

As FIG. 5 particularly indicates, the upper ends 72a of the U-shapedwires are secured by wire clamp bolts 73, which are threaded intoelongate openings 74 (See FIG. 5) provided in the bars 69b. The bolts 73have axial bores 75 in which the ends 72a of wires 72 are received. Nuts76 and washers 77 can be provided to clamp the bolts 73 and terminals76a in position and set screws 73a, provided in threaded openings 73b inthe heads of the bolts 73, are provided to clamp the wire ends 72asecurely in position. Insulated wires 76b lead from the terminals to asource of electrical current. Preferably, the source of electricalenergy will be rheostat-controlled to provide the current necessary toresistance-heat the wires 72 to the desired temperature for melting thefoam insulation board 13. It is to be emphasized that the wires 72 donot cut the board 13, but rather, melt the plastic in a continuousmanner as the board 13 moves past the wires 72 at a controlledpredetermined speed, so that the board 13 does not, in any manner,displace the wires 72 as it moves along, at the rate of feed provided bypowered rollers 30 and 33.

In addition to the shaping wires 72, the machine provides a transverelylinear, horizontal shaping wire 78 (see particularly FIGS. 3 and 4),which is mounted for vertical travel in a manner which now will bedescribed. The ends of the wires 78 are secured by wire clamps or wireclamp assemblies, generally designated 79 which include plates 80. Atone end of the machine the assemblies 79 comprise a plate 80, having athreaded opening 81 for receiving a bolt 73' of a construction identicalto the bolt 73 previously described. The down-turned ends 78a of wire 78are received in the openings 75 provided in the bolts 73', and similarlysecured by set screws 73a.

Also, as previously, nuts 76 clamp terminals 82 to washers 77 providedon the bolts 73', and feed wires 82a extend from the terminal 82 to asource of electrical energy for heating wire 78 to plastic board meltingtemperature. The opening 81b provided in one of the plates 80 iselongated, as shown at 80a at the top of FIG. 4, so that screws 73' canbe fixed in a position in which wire 78 is taut. As wire 78 is heated,it has been found that it significantly expands and loses its tension.For this reason, the wire clamp assembly 79 at one side of the machine,connects the plate 80 to a second plate 83 for slideable movementrelative thereto. Side posts 84, fixed to this plate 80, pass throughopenings 85 provided in the plate 86 securing to plate 83. Springs 87connected to the plate 86 connect to a plate 88 which is fixed to themovable plate 80, and exert a tension which continually maintains thewire 78 taut, even though the one plate 80 has moved relatively to theplate 83 to the 80' position, as shown in broken lines. Thus, regardlessof the expanded position of wire 78, the wire 78 is, at all times,maintained in a tensioned-taut condition.

Provided fixed between the frame top end rail 26a and an intermediaterail 26b, at each side of the machine, as illustrated in FIG. 3, a pairof guide rods 89 each of which pass through openings 90 provided in theclamp plate 80 at one end, and the plate 83 at the other, to be receivedin sockets 89a. The rods 89 extend up through openings 89b provided inthe sill 26a (FIG. 3) and are secured in position by nuts 89c. Journaledin bearings 91 and 92, intermediate the guide rods 89 at each side ofthe machine, is a threaded drive shaft 93, which passes through athreaded opening 94 in plate 83, and in the plate 80 at the oppositeside of the machine. The shafts 93 are rotatable, but axially fixed, sorotation of the shafts 93 in one direction, or the other, of rotation,operates to move the plate 83 and the plate 80 at the opposite side ofthe machine, upwardly and downwardly in unison to maintain thehorizontal position of the wire 78.

Motor 95 is coupled to the lower end of the one drive shaft 93 by asprocket 95a, chain 95b, and sprocket 95c, and directly drives the shaft93 at one side of the machine. The other shaft 93 is driven by motor 95indirectly, by a sprocket 96 via a chain 97, driving a sprocket 98 fixedto the other shaft 93. Motor 95 is a variable speed, reversible drive,electric motor, which is driven in correlation with the speed of motor39. Limit switches 99 and 100 are provided as safety switches to limitthe upward and downward movement of the plates 83 and 80 which travel onshafts 93.

THE OPERATION

In operation, if when it is desired to simply form the grooves 14 in theboard 13, the operator places the foam board 13 on the table 15, andmoves it to a position in which it is grasped by the pressure roll 56and the drive roll 33. The speed of travel of the board 13 is correlatedwith the speed at which the wires 72 melt the plastic board. The boardis fed at a rate of travel such that the flexible wires 72 are notdisplaced, and function to melt the plastic ahead of them as the board13 moves, rather than to physically cut. Variously grooved sheets can becut by loosening the bolts 72 and adjusting the vertical position ofplates 69, and by adjusting the position of bolts 73 in the slots 74.

Insulation board can be cut with a taper by feeding it through themachine with the wires 72 moved to elevated position out of the path ofthe board 13. As shown in FIG. 9, the wire 78 can initially be placed inthe position 78', and then, by energizing motor 95 and progressivelylowering the wire 78 to the 78" position via revolution of screw shafts93 as board 13 is fed longitudinally in the direction b, using hot wire78 to shape the board 13 with the taper a. The speed of motor 95 iscorrelated with the speed of advance of the board 13 (the speed of motor39), to accomplish the desired taper.

The hand wheels 52 and 63 permit raising or lowering of the pressurerolls 42 and 56 to adjust to the different thicknesses of board 13 itmay be desired to process. It is possible to cut transverse tapers inthe manner indicated in FIG. 8 by raising one of the wire clamps 80relative to the other. This requires the machine operator to back offthe nuts 89c to permit the rods 89 at one side of the machine to beraised upwardly out of sockets 89a, and out of the openings 90 in plate80. The plate 80 then can be manually rotated with respect to the screwshaft 93, and so raised with respect to the opposite wire clamp 80, asto dispose the wire 78 in horizontally tilted position. With the rods 89then lowered back through the openings 90 and secured in position,movement of the board 13 will cause wire 78 to melt the plastic ahead ofit and form the transverse taper x as shown in FIG. 8. A compound tapercan be provided by disposing the wire 78 in horizontally tilted positionto provide the transverse taper, and at the same time, driving the motor95 to progressively lower the wire 78 and provide a longitudinal taper.

While only several embodiments of the invention have been described indetail, it will be apparent to those skilled in the art that thedisclosed embodiment may be modified. Therefore, the foregoingdescription in all aspects is to be considered exemplary rather thanlimiting in any way, and the true scope of the invention is that definedin the following claims.

What is claimed is:
 1. In a portable plastic foam board insulationshaper for hot wire shaping insulation board to fit roof contours andthe like, the combination of elements comprising:a. a machine framehaving sides, and an entrance end and a discharge end; b. boardconveying means incorporated with the frame means for moving the boardalong a longitudinal pathway from the said entrance end to the saiddischarge end; c. a transversely disposed, generally horizontal linearwire, broadside to the said pathway mounted for movement into the pathof movement of the board, and extending generally from one side of theframe to the other; d. vertically extending guides defining sides forthe frame at each end of the wire; e. a pair of wire clamps for securingthe ends of the wire mounted for vertical movement along the guides; f.means mounting one of said wire clamps for transverse movement relativeto the other and said frame; g. yieldable means associated with said oneof said clamps and wire permitting expansion of said wire linearly whilemaintaining it under tension; h. means for heat energizing the wire tobring it to plastic board melting temperature; i. motor means fordriving said clamps to move them vertically in unison at a predeterminedspeed with relation to the speed of movement of said boards; j.transverse rail means supported by said frame; k. a series oftransversely spaced, generally U-shaped hot wires mounted on said railmeans to depend therefrom and form grooves in the upper surface of aboard passing in said pathway; l. wire clamp means associated with theends of said U-shaped hot wires to support them on said rail means; andm. means for heat energizing the U-shaped wires to bring them to plasticboard melting temperatures.
 2. The invention set forth in claim 1wherein said board conveying means comprises drive roll members at theentrance and discharge ends of the frame; and motor means for poweringsaid drive roll members.
 3. The invention set forth in claim 2 whereinentrance and discharge pressure roll members are provided above each ofsaid drive roll members axially parallel therewith; vertically extendingguides are provided at each side of the machine frame at the entranceand discharge ends; and manipulatable drive means is provided for movingthe pressure roll members vertically relative to the drive roll members.4. The invention set forth in claim 3 wherein the said transverse railmeans mounting said U-shaped hot wires is mounted for vertical travelalong the guides at the entrance end of the machine frame with saidentrance pressure roll member.
 5. The invention set forth in claim 3wherein said manipulatable drive means comprises rotatable, axiallyfixed screw shafts, bearings are provided for the ends of said pressureroll members, and brackets, with nuts received on said screw shafts,support said bearings and pressure roll members for veritcal travel. 6.The invention set forth in claim 1 wherein the means mounting said onewire clamp for transverse movement forms part of a wire clamp assemblycomprising a base plate with a transversely extending slide guide systemconstituting said mounting means for said one wire clamp, on which saidone wire clamp is received for transverse sliding movement; and saidyieldable means comprises biasing means connected between said baseplate and said one wire clamp and exerting a tension urging said onewire clamp toward the base plate.
 7. The invention set forth in claim 6wherein said biasing means comprises springs.
 8. The invention set forthin claim 1 wherein said motor means includes motor driven, rotatable,vertical screw shafts journaled by said frame at each side of themachine, and nuts are fixed on said base plate and other wire clamp,which are received on said screw shafts and travel vertically when saidscrew shafts are driven.
 9. The invention defined in claim 1 whereinsaid frame side guides comprise a pair of endwisely spaced guide rodsextending through slide bearing openings provided in said base plate andsaid other wire clamp on opposite sides of each of the screw shafts. 10.The invention defined in claim 9 wherein said guide rods at one side arereleasably mounted to be slid vertically out of said slide bearingopenings, and releasable means is provided for releasing the ends of thewire at that side from its wire clamp to permit rotative adjustment ofone wire clamp relative to the other to a vertical position out ofhorizontal alignment with the other to permit cutting a transversetaper.
 11. The invention defined in claim 1 wherein said wire clampmeans associated with the ends of said U-shaped hot wires includes boltmembers having axial bores therein for receiving the ends of theU-shaped hot wires, set screws provided in the bolt members for engagingthe ends of said U-shaped hot wires and fixing them in position in saidbores; bars with transversely elongate slots for receiving said bolts;means for securing the upper ends of said bolts in said slots, andclamping energizing wire terminals to said bolt members, hangers withvertically extending slots fixed to said bars; and means extendingthrough said slots for securing said hangers in adjusted position onsaid rail means.
 12. The combination defined in claim 11 wherein saidrail means includes members forming a transverse channel and said meansfor securing said hangers in adjusted position includes a series ofchannel-shaped parts fitting within said channel, and securing bolt andnut means fixed to said channel parts and extending through saidvertical slots in the hanger members.
 13. A method of shaping insulationboard to fit roof contours in a machine having board conveying means,for moving the board to be shaped along a longitudinal pathway; atransversely disposed, generally horizontal, linear wire, broadside tothe pathway in the path of movement of the board, extending generallyfrom one side of the frame to the other; a pair of wire clamps forsecuring the ends of the wire mounted for guided vertical movement;means mounting one of the wire clamps for transverse movement relativeto the other; means associated with the clamps for heat energizing thewire to bring it to plastic board melting temperature, and motor meansfor driving the clamps to move them vertically in unison; the steps of:applying an electric current to the wire to resistance heat it toboard-melting temperature, while moving one of the wire clampstransversely away from the other to maintain the wire linear and taut;driving the board along the longitudinal pathway at a rate of speed suchthat the wire continuously melts a groove in the board ahead of the wireand, while moving the board, vertically moving the wire clamps and wirein unison at a controlled, predetermined rate of speed with respect tothe movement of the board, to cut a tapered surface; and moving one ofthe wire clamps vertically relative to the other, before the board isfed, to dispose the wire in a horizontally inclined position and therebyform the board with a compound taper which is tapered in both thelongitudinal and transverse directions.
 14. A plastic foam boardinsulation shaper for hot wire shaping insulation board to fit roofcontours and the like comprising:a. a machine frame having sides,bounded by an entrance end and a discharge end; b. board conveying meansincorporated with the frame for moving the board along a longitudinalpathway from the said entrance end to the said discharge end; c. atransversely disposed, generally horizontal wire, broadside to the saidpathway mounted for movement into the path of movement of the board, andextending generally from one side of the frame to the other; d. a pairof wire clamps for securing the ends of the wire having slide bearingopenings therein; e. means for heat energizing the wire to bring it toplastic board melting temperature; f. motor means for driving saidclamps to move them vertically in unison at a predetermined speed withrelation to the speed of movement of said board, said motor meansincluding motor driven, rotatable, vertical screw shafts journaled bysaid frame at each side of the machine, and nuts connected with saidwire clamps, which are received on said screw shafts and travelvertically when said screw shafts are driven; and g. a pair of endwiselyspaced guide rods at each side of the frame extending through the slidebearing openings provided in said wire clamps, on opposite sides of eachof the screw shafts, said guide rods at one side of the frame beingreleasably mounted to be slid vertically out of said slide bearingopenings, releasable means being provided for releasing the end of thewire at that side from one of said wire clamps to permit rotativeadjustment of said other wire clamp on the screw shaft on which it isreceived to a vertical position out of horizontal alignment with thesaid one wire clamp.
 15. The invention set forth in claim 14 wherein themeans mounting said one wire clamp for transverse movement forms part ofa wire clamp assembly comprising: a base plate with a transverselyextending slide-guide system constituting said mounting means for saidone wire clamp, on which said one wire clamp is received for transversesliding movement; and said yieldable means comprises biasing meansconnected between said base plate and said one wire clamp and exerting atension urging said one wire clamp toward the base plate.
 16. Theinvention set forth in claim 15 wherein said biasing means comprisessprings.